Erosion behavior of Ti-hBN multifunctional coatings in a custom-made planetary test rig at extreme lunar temperatures

Spacecraft landings and takeoffs on the lunar surface, along with extreme temperature variations between day and night (−196 to 150º C), cause high-velocity dust impacts and erosion, resulting in the premature failure of structures. Ti/2 vol% hBN coatings were deposited using atmospheric (APS) and vacuum plasma spray (VPS) using cryo-milled powder feedstock to protect the structural components. The erosion performance of coatings at extreme lunar temperature regimes (−150 to 150 °C) was evaluated in a custom-made planetary erosion test rig (PETR) at low (50 mph) and high impact velocities (250 mph). The mass loss of VPS coatings was reduced by 50 % compared to the APS coatings and 40 % compared to the Ti6Al4V substrate. The cryogenic temperature induces brittleness in the material, rendering it susceptible to extreme conditions of material loss. The particle impact-deformation behavior was captured using a high-speed camera to study the erosion mechanism. This analysis revealed chipping in substrates and brittle APS coatings, while particles rebounding and embedding were observed in VPS coatings. Energy calculations, aided by particle trajectory tracking from the high-speed camera, have conclusively shown that VPS coatings absorb 5–10 % more energy than APS coatings during erosion tests. A modified erosion index was developed incorporating the fracture toughness and temperatures. New erosion models for brittle and ductile target materials are proposed for developing erosion-resistant material systems. [Display omitted] •Novel Ti-hBN coatings were tested on a custom rig simulating erosion in extreme conditions on the lunar surface.•Vacuum Plasma Sprayed (VPS) coatings showed 50 % less mass loss than APS under extreme temperatures from −196 °C to 150 °C.•VPS coatings showed enhanced energy absorbance and erosion resistance over APS coatings due to higher fracture toughness.•New semi-quantitative erosion models were developed for lunar conditions in brittle and ductile materials.